Method of manufacturing a stator assembly

Abstract

A method of manufacturing a stator assembly for an electric machine includes providing multiple stator windings. Each stator winding is connected to a conductive terminal. The method includes assembling multiple busbars into a busbar assembly. The busbars are arranged flexibly relative to each other in the busbar assembly. The method also includes connecting the busbar assembly to some of the conductive terminals.

1 . A method of manufacturing a stator assembly for an electric machine, the method comprising:
 providing a plurality of stator windings, each stator winding being connected to a conductive terminal;   assembling a plurality of busbars into a busbar assembly, wherein the plurality of busbars are arranged flexibly relative to each other in the busbar assembly; and   connecting the busbar assembly to a plurality of the conductive terminals.   
     
     
         2 . The method as claimed in  claim 1 , wherein each of the plurality of busbars is rigid. 
     
     
         3 . The method as claimed in  claim 1 , wherein the step of assembling the plurality of busbars into the busbar assembly comprises winding lacing tape around the plurality of busbars. 
     
     
         4 . The method as claimed in  claim 1 , wherein the step of assembling the plurality of busbars into the busbar assembly comprises arranging the plurality of busbars into two or more layers to form the busbar assembly. 
     
     
         5 . The method as claimed in  claim 4 , wherein the step of assembling the plurality of busbars into the busbar assembly comprises arranging a layer of insulation between the two or more layers of the busbar assembly. 
     
     
         6 . The method as claimed in  claim 5 , wherein the layer of insulation comprises a low-friction material. 
     
     
         7 . The method as claimed in  claim 4 , wherein the step of assembling the plurality of busbars into the busbar assembly comprises applying an adhesive or an epoxy between the two or more layers of the busbar assembly. 
     
     
         8 . The method as claimed in  claim 7 , wherein the method comprises curing the adhesive or the epoxy after the busbar assembly has been connected to the plurality of the conductive terminals. 
     
     
         9 . The method as claimed in  claim 1 , wherein the method comprises connecting the busbar assembly to a plurality of the conductive terminals so to connect at least four of the stator windings together for supplying a same phase of an AC voltage supply to these at least four stator windings. 
     
     
         10 . The method as claimed in  claim 9 , wherein the busbar assembly comprises at least 6 busbars. 
     
     
         11 . The method as claimed in  claim 1 , wherein the step of assembling the plurality of busbars into the busbar assembly comprises arranging the plurality of busbars in a flexible jig. 
     
     
         12 . The method as claimed in  claim 11 , wherein the method comprises connecting the busbar assembly to the plurality of the conductive terminals while the plurality of busbars are in the flexible jig. 
     
     
         13 . The method as claimed in  claim 12 , wherein the method comprises curing the flexible jig. 
     
     
         14 . The method as claimed in  claim 1 , wherein the method comprises:
 applying a coating to the busbar assembly; and   curing the coating.   
     
     
         15 . The method as claimed in  claim 1 , wherein the busbar assembly comprises an arc that subtends an angle 50 degrees and 360 degrees.